Water Heater

Feel the drive

e1
Thermo Top C Parking Heater 00 0002

Installation documentation

Opel
Astra / Astra Caravan / Astra GTC / Astra Twin Top
Petrol and Diesel
from Model Year 2004
Left-hand drive vehicle

WARNING!

Hazard warning:

Incorrect installation or repair of Webasto heating systems may cause a fire or result in the
emission of carbon monoxide, which can be fatal. Serious or fatal injuries can be caused as
a result.
Specialist company training, technical documentation, specialised tools and equipment are
required to install and repair Webasto heating and cooling systems.
Only original Webasto parts must be used. For this, also see the catalog of air and water heat-
er accessories from Webasto.
NEVER attempt to install or repair Webasto heating or cooling systems if you have not
successfully completed the company training and thereby acquired the required tech-
nical skills, or if you do not have access to the required technical documentation, tools
and equipment needed to carry out correct installation and repairs.
ALWAYS follow all Webasto installation and repair instructions and observe all warnings.
The initial startup is to be executed with the Webasto Thermo Test Diagnosis.
Webasto does not accept any liability for defects and damage that are attributable to installa-
tion by untrained staff.

Ident. No.: 1303051H_EN Fee Euro 10.00 Webasto AG

 Opel Astra

Table of Contents

Table of Contents 2
Validity 3
Foreword 4
General Instructions 4
Heater / Installation Kit 4
Special Tools 4
Explanatory Notes on Document 5
Preliminary Work 6
Heater installation location 6
Preparing wiring harness 7
Vehicles with automatic air-conditioning (ECC and SAC) 7
Vehicles with passenger compartment monitoring 7
Electrical system 8
Fan control 9
Vehicles with passenger compartment monitoring 7
Manual air conditioning without passenger compartment monitoring 10
Manual air conditioning with passenger compartment monitoring 11
Automatic A/C without passenger compartment monitoring (ECC and SAC) 12
Automatic A/C with passenger compartment monitoring (ECC and SAC) 13
Remote option (Telestart) 14
Combustion air 15
Preparing installation location 16
Preparing heater 18
Installing heater 18
Fuel 20
Metering pump 20
Fuel extraction 21
Coolant circuit 1.4 litre; 2.0 litre petrol 24
Coolant circuit of 1.6 litre Z16XEP; 1.8 litre petrol and 1.3 litre; 1.7 litre diesel 25
Coolant circuit 1.6 litre Z16XER 26
Coolant circuit 1.6 litre Z16LET 27
Coolant circuit 1.9 litre diesel 28
Cutting hoses to length 29
1.6 litre petrol Z16XEP 29
1.6 litre petrol Z16XER 29
1.6 litre petrol Z16LET 30
1.8 litre petrol 30
2.0 litre petrol 32
1.3 litre and 1.7 litre diesel 31
1.9 litre diesel 31
Preparing hoses 31
All vehicles 32
All vehicles except 2.0 litre petrol 32
2.0 litre petrol 32
Hose installation 33
1.6 litre petrol Z16XEP 29
1.6 litre petrol Z16XER 29
1.6 litre petrol Z16LET 30
1.8 litre petrol 30
2.0 litre petrol 32
1.3 litre diesel 40
1.7 litre diesel 41
1.9 litre diesel 31
Exhaust gas 45
Petrol 46
Diesel 46
All vehicles 32
Final Work 48
Template for fuel-tank sending unit 49
Template for Fuel Standpipe 50
Operating Instructions for End Customer 51

2
 Opel Astra

Validity
Manufacturer Model Type EG-BE-No. / ABE
Opel Astra H A-H e1*2001 / 116*0261
Opel Astra H A-H e1*2001 / 116*0293
Opel Astra H Twin Top A-H/C e4*2001 / 116*0094

Engine type Engine model Output in kW Displacement in cm

Z14XEL Petrol 55 1364
Z14XEP Petrol 66 1364
Z16XEP Petrol 77 1598
Z16XER Petrol 85 1598
Z16LET Petrol 132 1598
Z18XER Petrol 103 1796
Z18XE Petrol 92 1796
Z20LEH Petrol (OPC) 177 1998
Z20LEL Petrol 125 1998
Z20LER Petrol 147 1998
Z13DTH Diesel 66 1248
Z17DTL Diesel 59 1686
Z17DTH Diesel 74 1686
Z17DTJ Diesel 81 1686
A17DTJ Diesel 81 1686
Z17DTR Diesel 92 1686
A17DTR Diesel 92 1686
Z19DTL Diesel 74 1910
Z19DT Diesel 88 1910
Z19DTH Diesel 110 1910

Vehicle models, engine types, equipment variants as well as national specifications, which are
not listed in this installation documenation, have not been tested.
However, installation according to this installation documentation may be possible.

The installation location of a digital timer and summer/winter switch should be confirmed with the end
customer before installation.

3
 Opel Astra

Heater / Installation Kit

Quantity Designation Order No.:

1 Opel-specific delivery scope Thermo Top C Petrol 83343D
Opel Catalogue No.: 1734010
1 Opel-specific delivery scope Thermo Top C Diesel 83344D
Opel Catalogue No.: 1734011

Also required:

Quantity Designation Order No.:

1 Installation kit for Opel Astra 2004 Petrol and Diesel 1303047F
Opel Catalogue No.: 1734115
1 Heater control See Opel price list

Additionally required for 1.9 litre diesel

Quantity Designation Opel Order No.:

1 Bracket of vacuum valve 1734144

Foreword
This installation documentation applies to Open Astra H vehicles - for validity, see page 2 - from model
year 2004 and later, assuming technical modifications to the vehicle do not affect installation, any lia-
bility claims excluded. Depending on the vehicle version and equipment, modifications may be neces-
sary during installation with respect to this installation documentation.

However, where this is the case the stipulations in this "installation documentation" and "operating in-
structions" and the "installation instructions" for the Thermo Top C should be observed.
The corresponding rules of technology and any information from the vehicle manufacturer should be
observed during the installation work.

General Instructions
Installation should be carried out according to the general, standard rules of technology. Unless spec-
ified otherwise, fasten hoses, lines and wiring harnesses to original vehicle lines and wiring harnesses
using cable ties.
Sharp edges must be provided with rub protection (cut-open fuel hose)!
Spray unfinished body areas, e.g. drilled holes, with anti-corrosion wax (Tectyl 100K, Order No. 111329).

Special Tools
- Torque wrench for 2.0 - 10 Nm
- Hose clamping pliers
- Riveting pliers

4
 Opel Astra

Explanatory Notes on Document

To provide you with a quick overview of the individual working steps, you will find an identification mark
on the outside top right corner of the page in question.

Mechanical system

Electrical system

Coolant circuit

Fuel

Exhaust gas

Combustion air

Special features are highlighted using the following symbols:

Specific risk of injury or fatal accidents.

Specific risk of damage to components.

Specific risk of fire or explosion.

Reference to general installation instructions of Webas-

i to components or to the manufacturer's vehicle-specific
documents.

Reference to a special technical feature.

The arrow in the vehicle icon indicates the position on

the vehicle and the viewing angle.

5
 Opel Astra

Preliminary Work
Warning!
- Disconnect the battery earth connection.
- Remove the battery (only on 1.9 litre diesel vehicle).
- Depressurise the cooling system.
- Copy the factory number from the original type label to the duplicate type label.
- Remove years that do not apply from the duplicate label.
- Attach the duplicate label (type label) in the appropriate place.
- Remove the air filter together with the intake hose.
- Open the fuel tank cap and vent the fuel tank.
- Close the fuel tank cap again.
- Remove the front grill.
- Remove the bumper.
- Remove the front section of the wheel well trim on the right.
- Remove the horns.
- Remove the vacuum valve (only on 1.9 litre diesel vehicle).
- Remove the underride protection (depending on vehicle equipment).
- Remove the rear bench seat.
- Remove the service cover of the fuel-tank sending unit.
- Remove the lower instrument panel trim on the driver's side.
- Remove the glove compartment (only on vehicles with manual air conditioning).
- Remove the A/C control panel (only on vehicles with automatic air-conditioning).
- Remove the A-pillar trim in the footwell on the front passenger side.
- Remove the left-hand door sill cover completely (only on vehicles with alarm system).
- Open the cable duct under the door sill cover (only on vehicles with alarm system).

1 Heater installation location

(1) Heater

Installa-
tion loca-
tion

1
6
 Opel Astra

Preparing wiring harness

Vehicles with automatic air-condition-

ing (ECC and SAC)

1 Wire section 1 will be required later for con-

sw nection on A/C control panel. Cutting
0,75
wires to
100 length

Vehicles with passenger compart-

ment monitoring

Wire sections 2, 3, 4 and 5 will be required

later for switching off passenger compartment
monitoring.
2 3 4 5
sw Cutting
0,75 wires to
70 200 200 length

30

rt

86 87 87a

F3
K3
85 30
sw Premount-
rt/ws ing K3.1
sw relay with
passen-
sw ger com-
gn/ws br partment
monitor-
85 30 ing
X1 4 K3.1
HG
86 87 87a

sw sw

31
7
 Opel Astra

Electrical system
Wiring harness pass through Digital timer, summer/winter switch option
Detach bracket of wiring harness (2) from stud (1) Digital timer, drilling template
bolt (3). (2) Summer/winter switch, 12 mm dia. hole
(1) Protective rubber plug

1 2 1 2

2 3

sw
Electrical
Do not install the metering pump diagram
wiring harness until later togeth-
er with fuel line along the original
vehicle fuel lines on the under-
body

1 2 3 4 1

5
6 2

4 5

Fuse holder, K3 relay Additional K3.1 relay with passenger com-

(1) Original vehicle stud bolt (2/2), bracket of wir- partment monitoring
ing harness (2/3), plastic nut (1) Original vehicle stud bolt (2/2), bracket of wir-
(2) Angle bracket ing harness (2/3), K3.1 relay (2), plastic nut
(3) Retaining plate of fuse holder, M4x10 bolt, (2) K3.1 relay
washers, M4 nut
(4) Fuse holder
(5) Earth support point, 5.5x13 self-tapping screw
(6) k3 relay, 5.5x13 self-tapping screw

8
 Opel Astra

Fan control

1 Vehicles with passenger compart-

ment monitoring
Push included protective sleeving onto addi-
tional line (wire section 5) up to cable grom-
met in passenger compartment. Routing
Route additional line along left-hand A-pillar additional
in cable duct to rear line

(1) Black (sw) 0.75 mm wire section 5 from

K3.1/87

1 6

1 2 Passenger compartment monitoring is

switched off on rear zone module behind left-
hand luggage compartment trim.

(2) Wire section 5

(3) Connector X5 disconnected
(1) Socket of connector X5
Discon-
necting
connector

Dismantle connector X5. Cut off front cable

tie. Press both unlocking lugs toward rear
with small screwdriver and pull off connector
housing.

(1) Connector X5

Unlocking
connector

1 8

Connection on blue (bl) connector X5 from

rear zone module.
Produce connections according to wiring dia-
gram on Page 10 or 12, depending on vehicle
equipment.

(1) Connector X5, Pin 12

(2) Wire section 5 Connect-
1 ing line

Passenger compartment monitoring must be

reprogrammed to additional heating mode
with TECH 2 tester according to manufac-
2 9 turer's instructions.
9
 Opel Astra

1 Manual air conditioning without pas-

senger compartment monitoring
Connection on 5-pin connector of resistor
group R1_A60.
Produce connections as shown in wiring dia-
gram with blade connectors provided.
5
(2) 5-pin connector of resistor group Fan con-
(1) Violet (vi) wire from fan controls trol
4 (5) Red (rt) wire from K3/87a
(3) Violet (vi) wire to resistor of speed 2
(4) Black (sw) wire from K3/30

3 2 10

Webasto Opel i
30
15

rt FE4
F3 5 XC41
HG 30A
25A
X1 4 A1_A60
K15_X125
gn/ws rt/ws 4 3 2 1 30 86
XC41 Wiring dia-
or vi bl gn gram of
rt manual air
87 85
condition-
86 87 87a ing without
passenger
sw A1_X125 compart-
K3 ment moni-
85 30
4 1 2 5 toring
rt
+

1P M M5_A60
R1_A60 1P -
3 sw
br
sw
31

Webasto components Opel components Colours and symbols

HG TT-C heater FE4 Fan fuse rt red
X1 6-pin heater connector K15_X125 Fan relay ws white
F3 Fan fuse A1_A60 Fan controls sw black
K3 Fan relay R1_A60 Resistor group br brown
M5_A60 Fan motor gn green
Legend
vi violet
or orange
bl blue

X Cutting point
Wiring colours may vary.

10
 Opel Astra

Manual air conditioning with passen-

ger compartment monitoring
Produce connection in accordance with Fig-
ure 10 and Page 9.
Fan con-
Produce connections as shown in following
trol
wiring diagram with blade connectors provid-
ed.

Webasto Opel i
30
15

rt FE4
F3 5 XC41
HG 30A
25A
X1 4 A1_A60
K15_X125
gn/ws rt/ws 4 3 2 1 30 86
XC41
or vi bl gn
rt 87 85
86 87 87a Wiring dia-
gram for
K3 sw A1_X125 manual air
85 30 condition-
ing with
4 1 2 5 rt passenger
br + compart-
sw
ment moni-
3 M M5_A60 toring

sw 4 sw 2 1P
-
R1_A60 1P
sw
85 30 3
K3.1
sw 5
86 87 87a sw
12 X5

RZM

31

Webasto components Opel components Colours and symbols

HG TT-C heater FE4 Fan fuse rt red
X1 6-pin heater connector K15_X125 Fan relay ws white
F3 Fan fuse A1_A60 Fan controls sw black
K3 Fan relay R1_A60 Resistor group br brown
K3.1 Additional relay M5_A60 Fan motor gn green Legend
RZM Rear zone module vi violet
or orange
bl blue
X Cutting point
Wiring colours may vary.

11
 Opel Astra

1 2 Automatic A/C without passenger

compartment monitoring (ECC and
SAC)
Connection on grey (gr) 32-pin connector ZF
32 - 1, Pin 1 from A/C control panel.
Produce connections as shown in following wir-
ing diagram with blade connectors provided.
Replace F3 25 A fuse with 1 A fuse. Fan con-
trol
(1) Black (sw) wire from K3/30
(2) Wire section 1
(3) 32-pin grey (gr) connector ZF 32 - 1

3 11

Webasto Opel i
30
15

HG F3
1A
X1 4

rt/ws
! Wiring dia-
gn/ gram for
ws rt automatic
air-condi-
tioning
without
86 87 87a sw sw 1 passenger
compart-
K3 ment moni-
85 30 toring
(ECC and
1 ZF32-1 SAC)

KB

br
31

Webasto components Opel components Colours and symbols

HG TT-C heater KB A/C control panel rt red
X1 6-pin heater connector ZF 32 - 1 Grey (gr) connector KB ws white
F3 Replace 25 A with 1 A sw black
fuse. br brown
K3 Fan relay gn green
Legend

Insulate wire end and tie

back
X Cutting point
Wiring colours may vary.

12
 Opel Astra

Automatic A/C with passenger com-

partment monitoring (ECC and SAC)
Produce connection in accordance with Fig-
ure 11 and Page 11.
Fan con-
Produce connections as shown in following
trol
wiring diagram with blade connectors provid-
ed.

Webasto Opel i
30
15

HG F3
1A
X1 4

gn/ws rt/ws
!
rt
Wiring dia-
86 87 87a gram of au-
tomatic air-
K3 sw sw 1 condition-
85 30 ing with
passenger
compart-
br ment moni-
sw 1 ZF32-1 toring
3 (ECC and
KB SAC)
sw 4 sw 2

85 30 sw 5
K3.1
12 X5
86 87 87a
RZM

31

Webasto components Opel components Colours and symbols

HG TT-C heater KB A/C control panel rt red
X1 6-pin heater connector ZF 32 - 1 Grey (gr) connector KB ws white
F3 Replace 25 A with 1 A RZM Rear zone module with sw black
fuse. connector X5 br brown
K3 Fan relay gn green
Legend
K3.1 Additional relay

Insulate wire end and tie

back
X Cutting point
Wiring colours may vary.
13
 Opel Astra

1 2 Remote option (Telestart)

i
1 Receiver
2 5.5 mm dia.hole, M5x12 bolt, flanged nut [2x]
3 Bracket

3
Mounting
receiver

3 12

1 On vehicles without solar reflect wind-

screen.

1 Antenna

Mounting
antenna

13

1 1 On vehicles with solar reflect windscreen

(approval stamp on windscreen at lower
left "C"

Use provided fields 70 x120 mm 1.

Mounting
antenna

Warning!
When routing antenna cable in area of air-
bags, observe instructions of vehicle manu-
14 facturer.

1 Only with T100HTM

1 Temperature sensor T100HTM

Mounting
tempera-
ture sensor

15
14
 Opel Astra

1 Combustion air

1 Combustion air pipe

a = 200mm

Discard section X Cutting

combus-
tion air
pipe to
length
a

1 Ensure proper installation position of com-

bustion-air intake silencer, see "Installation i
Instructions.

1 Remove retaining clip and fasten wiring

harness above wheel well with cable tie

Premount-
ing intake
silencer

16

1 2 3 1 Combustion-air intake hose shortened

2 Intake silencer
3 Included clip with cable tie in existing hole

Premount-
ing intake
silencer

17

15
 Opel Astra

1 2 Preparing installation location

Cut included 200 mm long edge protection in

centre.

1 Wiring harness of heater

2 100 mm long edge protection
Mounting
edge pro-
tection

18

1 1 Cross member of bumper

2 100 mm long edge protection

Mounting
edge pro-
2 tection

19

1 With 2 horns, mount brackets as shown (de-

pending on vehicle equipment).

(1) Original vehicle bolt

Premount-
ing horns

20

1 Ensure freedom of movement of neighbour-

ing components.

(1) Original vehicle stud bolt, flanged nut

(2) Horn bracket
2

Mounting
horns

21
16
 Opel Astra

1 With 1 horn, mount bracket as shown. (de-

pending on vehicle equipment).
Ensure freedom of movement of neighbour-
ing components.
2
(1) Original vehicle stud bolt, flanged nut
(2) Horn bracket
Mounting
horns

1 22

1 2 1.9 litre diesel

2 Screw out silent block

1 Discard original vehicle bracket of vacuum
valve

Removing
original ve-
hicle
bracket

23

1 2 1 Bracket of vacuum valve: Opel Catalogue

No.: 1734144
2 Screw in silent block [2x]

Mounting
included
bracket

2 24

1 2 3 Bracket of vacuum valve

4 Original vehicle stud bolt, flanged nut of
horn bracket
2 Vacuum valve
1 Original vehicle flanged nuts

Mounting
vacuum
valve

4 3 1 25
17
 Opel Astra

1 All vehicles

Existing holes 1 [2x] will be used for installa-

tion of heater.

Mounting
bracket

1 26

1 2 Preparing heater

Tighten Ejot screws to 10 Nm.

1 Heater
2 Bracket
3 Ejot screw [2x]
Preparing
heater

3 27

1 2 Installing heater

1 Heater
3 Bracket
2 M6x50 bolt, 30 mm long spacer sleeve, M6
flanged nut
4 M6x50 bolt, large diameter washer, outside Mounting
diameter 22 mm, 30 mm long spacer heater
3 sleeve, large diameter washer, outside di-
ameter 17.6 mm, M6 flanged nut

1 2 1 Loosely mount bracket

2 Heater
3 Ejot screw [2x]
4 Copy hole pattern, drill 9 mm hole [2x]

4 Mounting
heater

3 28
18
 Opel Astra

1 2 Install bracket 1 on heater again.

Tighten Ejot screws to 10 Nm.

2 M6x20 bolt, spring lockwasher, large diam-

eter washer, M6 rivet nut
3 Ejot screw [2x]
4 M6x20 bolt, spring lockwasher, M6 rivet
nut Mounting
heater

4 29

1 1 Flexible pipe
2 27 mm dia. clamp
3 Heater

Mounting
2 combus-
tion-air in-
take pipe

3 30

19
 Opel Astra

Fuel
CAUTION!
Open the vehicle's fuel tank cap, ventilate the tank and then re-close the tank lock.

Catch any fuel running off with an appropriate container.

Install fuel line and metering pump wiring harness so that they are protected against stone impact. Un-
less specified otherwise, always fasten using cable ties.
Mount the fuel line and wiring harness with rub protection on sharp edges.

WARNING!
The fuel line and wiring harness are routed to the metering pump as shown in the wiring harness rout-
ing diagram.

1 (1) Mecanyl fuel line

(2) Hose section, 10 mm dia. hose clamp [2x]

Connec-
tion to
2 heater

31

(2) Mecanyl fuel line

(1) Metering pump wiring harness

2
1 Routing
lines

32

1 Metering pump
Ensure proper installation position of meter-
i
ing pump, see "Installation Instructions".
Installation location on left in front of vehicle
5 fuel tank.
2
(5) Angle bracket, drill out to 8.5 mm dia. on Installa-
3 short leg tion loca-
(1) Original vehicle bolt tion of
(4) Rubber-coated p-clamp metering
(3) Metering pump pump
(2) Silent block, flanged nut [2x]

4 33
20
 Opel Astra

1 2 3 Fuel line from heater 1 on pressure side of

metering pump 4.

(2) Hose section, 10 mm dia. hose clamp [2x]

(3) Wiring harness of metering pump, con-
nector mounted
4 (5) Cable tie Connec-
tion to me-
5 tering
pump

34

1 Fuel extraction
Vehicles with single-line system

Detach cover of fuel-tank sending unit and lay

slightly to one side for drilling. Watch for splin-
ters when drilling.
Preparing
(1) Fuel-tank sending unit fuel-tank
(2) Lay on template sending
(3) Copy hole pattern, drill 6 mm dia. hole unit

Further installation corresponds to that for

3 2 35 two-line system, as everything is identical.

1 Vehicles with two line system except

Z17DTR / A17DTR and Z17DTJ/A17DTJ

Detach cover of fuel-tank sending unit and lay

slightly to one side for drilling. Watch for splin-
ters when drilling.

(1) Fuel-tank sending unit

(2) Lay on template Preparing
(3) Copy hole pattern, drill 6 mm dia. hole fuel-tank
sending
unit

3 2 36

1 1 Shape fuel standpipe 1 according to tem-

plate, cut to length and install, see "installa- i
tion instructions".

Installing
fuel stand-
pipe

37
21
 Opel Astra

1 2 Install fuel-tank sending unit according to

manufacturer's instructions.

(1) Fuel-tank sending unit

(2) Fuel standpipe
(5) Remaining section of Mecanyl fuel line
4 (3) Hose section
(4) 10 mm dia. Caillau clamp [2x] Connect-
ing fuel
5 line

4 3 38

1 1.7 litre Diesel Z17DTR / A17DTR

and Z17DTJ / A17DTJ

Detach cover of fuel-tank sending unit 1 and

lay slightly to one side for drilling. Watch for
2 splinters when drilling.

(2) Lay on template

3 (3) Copy hole pattern, drill 6 mm dia. hole Preparing
fuel-tank
sending
unit

39

1 1 Shape fuel standpipe 1 according to tem-

plate, cut to length and install, see "installa- i
tion instructions".

Installing
fuel stand-
pipe

40

1 2 3 Install fuel-tank sending unit 1 in accordance

with manufacturer's instructions.

(2) Fuel standpipe

(3) Fuel line, hose section, 10 mm dia. Caillau
clamp [2x]
4
Connect-
ing fuel
5 line

4 3 41
22
 Opel Astra

1 2 3 4 Fuel line from fuel standpipe 3 on intake side

of metering pump 1. Slide fuel hose 4 as pro-
tective hose onto fuel line 3.
5 Check the position of the components; adjust
if necessary. Check that they have freedom of
movement.
Connec-
(2) Hose section, 10 mm dia. hose clamps [2x] tion to me-
(5) Cable tie tering
pump

42

23
 Opel Astra

Coolant circuit 1.4 litre; 2.0 litre petrol

WARNING!
Any coolant running off should be collected using an appropriate container. Route coolant hoses kink-
free. Unless specified otherwise, always fasten using cable ties. Position clamps so that other hose
cannot be damaged. The heater must be filled with coolant when installing the hoses.
The connection should be "inline" based on the following diagram:

22
Hose in-
A stallation
diagram
22

1 1

All spring clips without a specific designation = 27 mm dia.

All connecting pipes = 15x20 mm dia.
1 = Black (sw) rubber isolator [2x] only with 2.0 litre petrol.

24
 Opel Astra

Coolant circuit of 1.6 litre Z16XEP; 1.8 litre petrol and 1.3 litre; 1.7 litre diesel

WARNING!
Any coolant running off should be collected using an appropriate container. Route coolant hoses kink-
free. Unless specified otherwise, always fasten using cable ties. Position clamps so that other hose
cannot be damaged. The heater must be filled with coolant when installing the hoses.
The connection should be "inline" based on the following diagram:

22

Hose in-
C stallation
diagram
A 20x20

22

All spring clips without a specific designation = 27 mm dia.

All connecting pipes without a specific designation = 15x20 mm dia.

25
 Opel Astra

Coolant circuit 1.6 litre Z16XER

WARNING!
Any coolant running off should be collected using an appropriate container. Route coolant hoses kink-
free. Unless specified otherwise, always fasten using cable ties. Position clamps so that other hose
cannot be damaged. The heater must be filled with coolant when installing the hoses.
The connection should be "inline" based on the following diagram:

22

Hose in-
stallation
diagram

1 1
22

All spring clips without a specific designation = 27 mm dia.

Connecting pipe = 15x20 mm dia.
1 = Black (sw) rubber isolator [2x].

26
 Opel Astra

Coolant circuit 1.6 litre Z16LET

WARNING!
Any coolant running off should be collected using an appropriate container. Route coolant hoses kink-
free. Unless specified otherwise, always fasten using cable ties. Position clamps so that other hose
cannot be damaged. The heater must be filled with coolant when installing the hoses.
The connection should be "inline" based on the following diagram:

Hose in-
stallation
22 diagram

A
22

1 1

All spring clips without a specific designation = 27 mm dia.

All connecting pipes = 15x20 mm dia.
1 = Black (sw) rubber isolator [2x].

27
 Opel Astra

Coolant circuit 1.9 litre diesel

WARNING!
Any coolant running off should be collected using an appropriate container. Route coolant hoses kink-
free. Unless specified otherwise, always fasten using cable ties. Position clamps so that other hose
cannot be damaged. The heater must be filled with coolant when installing the hoses.
The connection should be "inline" based on the following diagram:

25
Hose in-
A stallation
diagram
25

All spring clips without a specific designation = 27 mm dia.

All connecting pipes = 18x20 mm dia.

28
 Opel Astra

Hose 1: Cutting hoses to length

A X

1.4 litre petrol

Cut away hose A just behind elbow.

a = 1600mm
b = 1500mm
a
X
Discard section X Cutting
Hose 2: hoses to
B X
length

Hose 1: A X
1.6 litre petrol Z16XEP

Cut away hose A just behind elbow.

a = 1600mm
b = 1600mm
c = 100mm

a Discard section X
X
Cutting
Hose 2: hoses to
B C
length

b c

Hose 1: 1.6 litre petrol Z16XER

A X
Cut away hose A just behind elbow.

a = 1800mm
b = 1460mm

Discard section X
a
X
Cutting
Hose 2: hoses to
B X
length

29
 Opel Astra

Hose 1: 1.6 litre petrol Z16LET

A X
Cut away hose A just behind elbow.

a = 1440mm
b = 1280mm

Discard section X
a
X
Cutting
Hose 2: hoses to
B X
length

Hose 1: 1.8 litre petrol

A X
Cut away hose A just behind elbow.

a = 1700mm
b = 1600mm

Discard section X
a
X
Cutting
Hose 2: hoses to
B length
C

Hose 1: 2.0 litre petrol

A X
Cut away hose A just behind elbow.

a = 1400mm
b = 1300mm

Discard section X
a
X
Cutting
Hose 2: hoses to
B X
length

30
 Opel Astra

Hose 1: 1.3 litre and 1.7 litre diesel

A X
Cut away hose A just behind elbow.

a = 1700mm
b = 1550mm

Discard section X
a
X
Cutting
hoses to
Hose 2: B
C length

Hose 1: 1.9 litre diesel

A X
Cut away hose A just behind elbow.

a = 2000mm
b = 1520mm

Discard section X
a
X
Cutting
Hose 2: hoses to
B X
length

1
Preparing hoses
2
1 Divide braided protection hose in centre.
1
2
1 (3) Braided protection hose complete [2x]
(2) Braided protection hose cut to length [2x]
3 (1) Cut heat shrink plastic tubing [6x] in centre
Preparing
3 hoses
A
B
1

1 43

31
 Opel Astra

1 B Routing hoses

All vehicles

1 27 mm dia. spring clip [2x]

Connec-
tion to
heater

1 A 44

B (1) 40 mm spacer nut, rubber-coated p-clamp [2x],

M6x20 bolt, spring lockwasher
(2) M6x50 bolt, spring lockwasher, large di-
A
ameter washer

Fastening
on engine
1 support

2 45

1 2 B All vehicles except 2.0 litre petrol

(1) M6x50 bolt (engine side to wheel well),

large diameter washer, pin lock
(2) 20 mm shim
(3) Rubber-coated p-clamp, 48 mm dia. Fastening
on frame
side carri-
er

3 A 46

1 2 3 4 B 2.0 litre petrol

(1) Perforated bracket
(3) M6x20 bolt (engine side to wheel well), pin
lock
(2) M6x20 bolt (wheel well to engine side), Fastening
flanged nut [2x each] on frame
(4) 29 mm dia. rubber-coated p-clamp [2x] side carri-
er

4 2 A 47
32
 Opel Astra

B A Hose installation

1.4 litre petrol

Route coolant hose to cutting point.

Routing in
engine
compart-
ment

48

1 (1) Hose section of heat exchanger inlet

(2) Engine outlet hose section

Cutting
point

2 49

(1) Hose of engine outlet

Connec-
A tion to en-
gine outlet

50

B 1 Before connecting, fill the water hoses with

coolant.

(1) Hose on heat exchanger inlet

Connec-
tion to
heat ex-
changer
inlet

Align hoses A and B over entire length and fix

51 in place with cable ties.
33
 Opel Astra

A B 1.6 litre petrol Z16XEP

Route coolant hose to cutting point.

Routing in
engine
compart-
ment

52

1 (1) Hose section of heat exchanger inlet

(2) Engine outlet hose section

Cutting
point

2 53

A (1) Hose of engine outlet

Connec-
tion to en-
1 gine outlet

54

C 1 Before connecting, fill the water hoses with

coolant.
Long side of 180 elbow on hose (1).

(1) Hose on heat exchanger inlet Connec-

tion to
heat ex-
changer
inlet

Align hose A, B and C over entire length and

B 55 fix in place with cable ties.
34
 Opel Astra

1 2 1.6 litre petrol Z16XER

(1) Original vehicle nut

(2) Angle bracket

Routing in
engine
compart-
ment

56

1 1 (1) Black (sw) rubber profile [2x]

B (2) Rubber-coated p-clamp, 48 mm dia.
(3) M6x20 bolt, flanged nut

Routing in
engine
compart-
3 ment

2 A 57

B Position rubber profiles as shown

Routing in
engine
compart-
ment

A 58

1 Remove engine/heat exchanger hose group 1

and cut off at markings. Centre section 3 is vul-
canized and remains on hose group (without
function).

(1) Remount engine/heat exchanger hose

group
(2) Remount hose section on engine outlet Cutting
(4) Discard hose section point

4 3 2 59
35
 Opel Astra

1 2 (1) Engine/heat exchanger hose group

mounted
(2) Centre section of hose group (without
function)
(3) Connection piece on engine outlet

Connec-
tion to en-
gine outlet

3 A 60

1 Before connecting, fill the water hoses with

coolant.

(1) Hose section on heat exchanger inlet

mounted Connec-
tion to
heat ex-
changer
inlet

Align hoses A and B over entire length and fix

in place with cable ties.
B 1 61 Align black (sw) rubber profiles.

1 2 1.6 litre petrol Z16LET

(1) Original vehicle nut

(2) Angle bracket

Routing in
engine
compart-
ment

62

1 1 (1) Black (sw) rubber profile [2x]

B (2) Rubber-coated p-clamp, 48 mm dia.
(3) M6x20 bolt, flanged nut

Routing in
engine
compart-
3 ment

2 A 63
36
 Opel Astra

B Position rubber profiles as shown

Routing in
engine
compart-
ment

A 64

Cut off hose on engine outlet/heat exchanger

inlet at marking.

(1) Hose section of heat exchanger inlet

(2) Engine outlet hose section

Cutting
1 point

65

1 (1) Hose section on heat exchanger inlet

turned approx. 90 to right

Connec-
tion to
heat ex-
changer
inlet

B 66

Before connecting, fill the water hoses with

coolant.

(2) Engine outlet hose section

(1) Insert spacer bracket
Connec-
tion to en-
1 gine outlet

Align hoses A and B over entire length and fix

in place with cable ties.
A 2 67 Align black (sw) rubber profiles.
37
 Opel Astra

B A 1.8 litre petrol

Route coolant hose to cutting point.

Routing in
engine
compart-
ment

68

(1) Hose section of heat exchanger inlet

(2) Engine outlet hose section

Cutting
point
1

2 69

A (1) Hose of engine outlet

Connec-
tion to en-
1 gine outlet

70

C 1 Before connecting, fill the water hoses with

coolant.
Long side of 180 elbow on hose (1).

(1) Hose on heat exchanger inlet Connec-

tion to
heat ex-
changer
inlet
B

Align hose A, B and C over entire length and

71 fix in place with cable ties.
38
 Opel Astra

1 2 2.0 litre petrol

(1) Original vehicle nut

(2) Angle bracket

Routing in
engine
compart-
ment

72

1 1 (1) Black (sw) rubber profile [2x]

B (2) Rubber-coated p-clamp, 48 mm dia.
(3) M6x20 bolt, flanged nut

Routing in
engine
compart-
3 ment

2 A 73

B Position black (sw) rubber isolator as shown

Routing in
engine
compart-
ment

A 74

1 (1) Engine outlet hose to heat exchanger inlet

Removing
hose

75
39
 Opel Astra

1 2 2 (1) Hose section of heat exchanger inlet

(2) 15x20 mm dia. connecting pipe; 22 mm
dia. spring clip [2x]
(3) Engine outlet hose section
(4) Discard section

Cutting
3 point

4 76

B 1 (1) Premounted hose section on heat ex-

changer inlet

Connec-
tion to
heat ex-
changer
inlet

77

Before connecting, fill the water hoses with

coolant.

(1) Premounted hose section on engine outlet

B

1 Connec-
tion to en-
gine outlet

Align hoses A and B over entire length and fix

in place with cable ties.
A 78 Align black (sw) rubber profiles

A 1.3 litre diesel

Route coolant hose to cutting point.

(1) Original vehicle stud bolt, rubber-coated

p-clamp, plastic nut
Routing in
engine
1 compart-
ment
B

79
40
 Opel Astra

(1) Hose section of heat exchanger inlet

(2) Engine outlet hose section

1
2 Cutting
point

80

B 1 (1) Hose on heat exchanger inlet

Connec-
tion to
heat ex-
changer
inlet

C 81

1 A Before connecting, fill the water hoses with

coolant.

(1) Hose of engine outlet

Connec-
tion to en-
gine outlet

Align hose A, B and C over entire length and

82 fix in place with cable ties.

A 1.7 litre diesel

Route coolant hose to cutting point.

(1) Original vehicle stud bolt, rubber-coated

p-clamp, 29 mm dia. plastic nut
Routing in
engine
1 compart-
ment
B

83
41
 Opel Astra

(1) Hose section of heat exchanger inlet

(2) Engine outlet hose section

Cutting
point
1

84

1 C (1) Hose on heat exchanger inlet

Connec-
tion to
heat ex-
changer
inlet

B 85

A Before connecting, fill the water hoses with

coolant.

(1) Hose of engine outlet

Connec-
tion to en-
1
gine outlet

Align hose A, B and C over entire length and

86 fix in place with cable ties.

B 1.9 litre diesel

Route coolant hose to cutting point.

(1) Original vehicle stud bolt, rubber-coated

p-clamp, plastic nut
Routing in
engine
compart-
ment

1 87
42
 Opel Astra

B A

Routing in
engine
compart-
ment

88

1 (1) Engine outlet hose to heat exchanger inlet

Removing
hose

1 89

1 Protective hose removed before cutting.

(1) Engine outlet hose section

(2) Hose section of heat exchanger inlet

Cutting
point

2 90

1 A (1) Hose of engine outlet

(2) Spacer bracket

Connec-
tion to en-
gine outlet

2 91
43
 Opel Astra

B 1 Before connecting, fill the water hoses with

coolant.
Align hose section from heat exchanger inlet (1)
to right when installing.

(1) Hose on heat exchanger inlet

Connec-
tion to
heat ex-
changer
inlet

92

1 View from below.

(1) Hose on heat exchanger inlet

Connec-
tion to
heat ex-
changer
B
inlet

Align hoses A and B over entire length and fix

93 in place with cable ties.

44
 Opel Astra

1 2 Exhaust gas

(1) Exhaust pipe

a = 200mm
(2) Exhaust end section
b = 100mm
Preparing
Discard section X exhaust
pipe

a b

1 1 Bracket
2 M6x20 bolt, flanged nut
3 Silencer

Installing
silencer

3 2 94

1 4 Exhaust elbow
2 Exhaust pipe
4 3 Red (rt) rubber isolator
1 Hose clamp [3x]

1
Mounting
3 exhaust
pipe

2 1 95

1 2 4 Exhaust silencer
3 Exhaust end section
1 Hose clamp
2 Position red (rt) rubber isolator [2x]
4
Mounting
exhaust
pipe and
end sec-
tion

96
45
 Opel Astra

100mm Petrol

60mm
Design of underride protection/wheel well
trim is dependent on vehicle equipment

Cut out underride protection/wheel well trim

90mm
75mm
on marking. Underride
protec-
tion/wheel
well trim
70mm

20mm
115mm
97

1 (1) 42 mm dia. hole

Underride
protection
/ wheel
well trim
90mm

50mm
98

2 Diesel

Design of underride protection/wheel well

trim is dependent on vehicle equipment

Cut out underride protection/wheel well trim

on marking. Underride
90 mm

protec-
(1) 42 mm dia. hole tion/wheel
well trim

50 mm

99

1 All vehicles

Check the position of the components; adjust

if necessary. Check that they have freedom of
movement.

(1) Underride protection / wheel well trim

(2) Red (rt) rubber isolator positioned with Underride
2 groove in trim protec-
(3) Exhaust end section tion/wheel
well trim

3 100
46
 Opel Astra

1 (1) Wheel well trim

(2) Premounted bolt from fastening of coolant
hoses
(3) Flanged nut and large diameter washer
22mm dia.

2
Wheel well
trim

3 101

47
 Opel Astra

Final Work

WARNING!
Mount removed parts in reverse order. Check all hoses, clamps and all electrical connections for firm
seating. Insulate and tie back all loose wires.
Only use manufacturer-approved coolant. Spray heater components with anti-corrosion wax
(Tectyl 100K, Order No. 111329).
- Connect the battery.
- Fill and bleed the coolant circuit according to the vehicle manufacturers specifications.
- Set the digital timer, teach Telestart transmitter
- Make settings on A/C control panel according to the "Operating Instructions for End Cus-
tomer".
- Place the "Switch off parking heater before refuelling" signboard in the area of the filler
neck
- For initial start-up and function check, see installation instructions i

Feel the drive

Webasto AG
Postfach 80
D-82132 Stockdorf / Germany
National Hotline: 01805 93 22 78
(14 Cent aus dem deutschen Festnetz)
Hotfax: 0395 5592 353
Hotmail: technikcenter@webasto.com
http://www.webasto.com

1303051H_EN Printed in Germany 05/2012 Printing: Steffen 48

 Opel Astra

Template for fuel-tank

sending unit

The template is dependent on the

respective vehicle equipment.

All vehicles
except Z17DTR / A17DTR and
Z17DTJ / A17DTJ:

6 mm dia.

6 mm dia.

Z17DTR / A17DTR
and Z17DTJ / A17DTJ:

100mm

Scale 1:1

Compare size of the printed version with dimension lines.

Allowed tolerance 2%.

Correct pressure settings appropriately in case of major devi-

ations or request original printout.

100mm
0

49
 Opel Astra

Template for Fuel Standpipe

100mm

Scale 1:1

Compare size of the printed version with dimension lines.

Allowed tolerance 2%.

Correct pressure settings appropriately in case of major devi-

ations or request original printout.

100mm
0

50
 Opel Astra

Operating Instructions for End Customer

Please remove page and add to the vehicle operating instructions.
Passenger compartment monitoring, when installed, is deactivated
when operating the parking heater.
Before parking the vehicle, make the following settings:

(1) Set air distribution to "Defrost"

(2) Set temperature to "max."

1
Vehicles
with
"Heating
and venti-
lation sys-
tem"

2 102

(1) Set air distribution to "Defrost"

(2) Set temperature to "max."

1 Vehicles
with "Auto-
matic air
condition-
ing" (SAC)

2 103

Observe the sequence of the settings

(see following figure).

(3) Air distribution upward

(1) Set temperature to "max."
2 (2) Set fan to level "3" Vehicles
1
with "auto-
matic
air-condi-
tioning
(ECC)
104

Vehicles
with "auto-
matic
air-condi-
tioning"
(ECC)

105
51